Process for manufacturing high-loft,nonwoven fabric

ABSTRACT

A METHOD OF MAKING A HIGH-LOFT, NONWOVEN FABRIC WITH A SUBSTANTIALLY CONTINOUS BACKING LAYER OF ADHESIVE AND A MULTIPLICITY OF FIBERS LOOPED OUTWARDLY FROM THE BACKING, BY FIRST EMBEDDING A WEB OF FIBERS IN A LAYER OF ADHESIVE AND THEN GATHERING THE ADHESIVE WHILE SOFTENED INTO A SUBSTANTIALLY CONTINUOUS BACKING LAYER WHILE SIMULTANEOUSLY LOOPING THE FIBERS OUTWARDLY FROM THE BACKING IN CERTAIN INSTANCES, THE LOOPS MAY BE SUBSEQUENTLY SHORN. THE BACKING MAY BE STRETCHED OR PERFORATED, OR THE FABRIC MAY BE LAMINATED TO AN ADDITIONAL BACKING OR BACKINGS TO CHANGE THE FINAL CHARACTERISTICS OF THE PRODUCT.

R. J. STUMPF July 2, 1974 PROCESS FOR MANUFACTURING HIGH- ,Fled July lO, 1972 LOFT, NONWOVEN FABRIC lO Sheets-Sheet l R. J. STUMPF July zu, 1974 PRocEss FOR MANUFACTURING HIGH-Low, uoxwovnn FABRIC .Filed July 10, 1972 lO Sheets-Sheet 2 y R. J. STUMPF July 2, 1974 PROCESS FOR MANUFACTURING HIGH-LOFT, NONWOVEN FABRIC .Filed July 10, 1972 Sheets-.Sheet 5 July 2,1914

R. J. STUMPF PROCESS FOR MANUFACTURING HIGH-LOFT, NONWOVEN FABRIC .Filed July 10, 1972 lO Sheets-Sheet l R. J. srUMPF July 2, 1974 PROCESS FOR MANUFACTURING HIGH-LOFT, NONWUVEN FABRIC l0 Sheets-Sheet 5 yFiled July l0, 1972 July 2. 1974 R. J. sruMPF 3,822,162

PROCESS FOR MANUFACTURING HIGH'LOFT, NQNWOVEN FABRIC AFiled .muyv 1o, 1972 l A 1o sheets-sheet e Mmmm July 2, 1974 R.

J. STUMPF BZ PROCESS FOR MANUFACTURING HIGH-LOFT, NONWOVEN FABRIC .Filed July 10, 1972 M4K/f @Wirf/afa? 1o sheets-sheet v m @Wiz/mv July 2, 1974 R. J. STUMPF PROCESS FCR MANUFACTURING HIGHLOF'T, NONWOVEN FABRIC .Filed July l0, 1972 www July 2, 1974 PROCESS FOR .Filed July l0, 1972 MANUFACTURING HIGH-LOFT, NONWOVEN FABRIC lO Shaats-Sheet 9 R. J. STUMPF PROCESS FOR MANUFACTURING HIGH-LOFT, NONWOVEN FABRIC .Filed July l0, 1972 nited States Patent-*difice .ABsTRAcToF THE DISCLOSUREv f-Amethod of making a high-loft, nonwovenfabricwith at'substantially Vcontinuous backing layer of adhesive and 3,822,162 Patented July 2, 1974 use and disposable products, such as: sanitary supplies, hospitalgarments, disposable sheets, and the like. For these applications the nonwoven fabric is generally made in ycontinuous sheet form with one or more layers of staple length fibers and/or a reinforcing scrim structure adhesively bonded together or laminated between plies of other material such as cellulosic wadding and plastic sheeting.

a 'multiplicity of berslooped outwardly from the "backingfby firstembedding a web of ylibers in alayer` ofadhesive and` then gathering the adhesive'while'softened into" a substantially continuous backing layer while. simultalneouslylooping the fibers 'outwardly from -the'backing ln certain instances,the loops may be subseqiiently shorn,

the backing may be stretched or perforated, or the-v fabric may be laminated-to an additional backingor `backings to change the final characteristics of the product.

VThe fibers may be natural, synthetic or various blends and, of course, the particular composition of the non- ,yvoven fabric-is greatly influenced by its intended use.

, Exemplaryof such nonwoven fabrics are those disclosed in U.S. Pat. Nos. 2,902,395, 3,047,444, 3,072,511, 3,327,- 708, 3,484,330, 3,553,604 and 3,553,605 and the aforesaid copending U.S. patent application, Ser. No. 79,287, all of which are assigned to the same assignee as the present application. While the products disclosed in the foregoing 'issued patents and copending applications have many different attributes and characteristics, they all have one thing inl common-viz., the principal fibers are nearly all disposed substantially parallel to the surfaces of the nonwoven material. As a result, the material is either relatively thin and -iiat or, such substantial thickness and surface texture as are imparted to the fabric are provided by creping or embossing various layers of the material or, in vvsome instances, the final nonwoven fabric.

It isgalso well known that natural fibers, particularly cotton and wool, have an inherent kink or crimp resulting from the way in which these fibers grow. This natural crimp is, of course, highly beneficial and contributes largely to the strength of thread made of a multiplicity of Vstaple'length fibers. In addition, it is the natural crimp of .these fibers that imparts certain characteristics of tex- Robert J. Stumpf, Ser. No. 769,959, filed Oct. 23, 1968,

now abandoned `and replaced by Ser. -No. 31,225, tiled Apr. 23, 1970, now U.S. Pat. No. 3,709,768.v -1 'i l Robert I. Stumpf, Ser. No. 820,224, iledrApr. 29, 1969, 110Wu-U.S. Pat. No. 3,687,754. v Robert] .Stumpf, Ser. No. 856,793,-ii1ed Sept. 10, 1969 now;U.S.;P`at. ,N,o. 3,720,554.

Robert I. Stumpf and William J. Mattes, Ser. No. 23,929, filed Mar.30, 1970, now U.S. P at. No. 3,687,796.

'-;.Robert I. Stumpf and William I. Mattes, Ser. No.

30,900, iled Apr. 22, 1970, now abandoned. v

Robert I. Stumpf andWilliam l. Mattes, Ser. No. `144,- 241, tiled May 17, 1971, now abandoned.. Herman G. Minshell, Robert J. Stumpf and William I. Mattes, Ser. No. 77,840, filed Oct. 5, 1970, now U.S.lP-at. No.;3,729,353. Adrian-D. Drost, Ser. No. 175,559, -iled Aug.'27, 1970', now abandoned. Adrian D.Drost and ARonald P. Glanz, Ser. No. 1.70,- 599, filed Aug. .10, 1970, now U.S. Pat. No.` y3,714,720.-

TI-,IE INVENTION This isparticularly true in the case ofv materials for singlef` ture and body to materials Woven therefrom.

In contrast, synthetic fibers, as initially formed, do not have any'appreciable kink or crimp since they are generallyv formed in continuous monoilaments. However, it is also well known that most synthetic fibers can be crimped and heat-setby passing the fibers through a heated stuffing box. o

lIt `is the primary aim of the present invention to provide a-methodfof making a nonwoven material which differs from the above and which is characterized by the gathering of a soft, tacky adhesive layer in which flexible ele..- mentssuch as fibers are embedded at spaced pointson the .elements while simultaneously looping the elements, to form a gathered adhesive backing layer with a fibrous surface, therebyY producing a novel high-loftv fabric with a pleasing surface texture and appearance.

It is a more particular object to provide a simple,eco nomical and high speed production method of making a high-loft, nonwoven fabric from a web of bers havingvan openadhesive pattern previously printed on one side by consolidating the adhesive into a substantially continuous backing-sheet while simultaneously loopingthe fibers' out# wardly from the adhesive backing sheet. A further object of the invention is the provision' of a method for making high-loft, vnonwoven fabrics char'- acterized by `having improved strength characteristics; in the cross-direction'of the fabric being produced. w

A". related object of the invention is the provisionof amethod of makinga high-loft, nonwoven-fabric in which the substantially continuous adhesive backing layer from whichy the fibers loop outwardly may"subsequent1y1be stretched, perforated or otherwisel opened to form a dis continuous backing layer. 'Y

1 Itis a further object to provide a method as described above which permits blending together fibers of dilei or appearance.

ing colors or other characteristics in the initial web in order to` achieve a` high-loft, nonwoven fabric having a colored pattern or other desired characteristics of texture 'In one of its more specific aspects, it is an object of the invention to provide a simple and economical method of making a laminated, high-loft, nonwoven fabric from a web of fibers embedded at longitudinally spaced points on the fibers in a layer of adhesive, by consolidating or gathering the adhesive into a substantially continuous backing sheet while simultaneously looping the fibers outwardly from the backing, and thereafter laminating the fabric thus formed to an additional backing layer for the purpose of increasing the strength of the overall fabric and/or otherwise altering the characteristics of the fabric and its backing.

Other objects and advantages of the present invention will become more readily apparent upon reading the following detailed description and upon reference to the attached drawings, in which:

FIG. 1 is a schematic view, in side elevation, of one form of apparatus which may be employed to practice the method of the present invention;

FIG. 2 is a fragmentary plan view of an illustrative web of base material while still supported on a conveyor belt, somewhat simplified and exaggerated for the sake of clarity of illustration, with portions broken away to expose the various layers;

FIG. 3 is a fragmentary plan view of one embodiment of the product of the present invention;

FIGS. 4 and 5, respectively, are greatlyfenlarged, simplified, and somewhat exaggerated sectional views taken substantially along the lines 4-4 and 5-5 in FIG. 3;

FIG. 6 is an enlarged schematic detail lview, in side elevation, of the forming drum and gathering blade of the apparatus shown in FIG. l;

FIG. 7 is an enlarged schematic side elevational view illustrating, in somewhat idealized fashion, successive stages in the sequence of gathering and looping of individual fibers;

FIG. 8 is an enlarged schematic fragmentary view, taken substantially along the line 8-8 of FIG. 7, here showing a fragment of the fiber web and adhesive pattern with illustrative fibers attached to the adhesive;

FIG. 9 is a simplified schematic view, taken substantially along the line 9-9 of FIG. 7, here showing the fragment of the fiber web and adhesive pattern depicted in FIG. 8 at a later stage in the loop forming sequence;

FIG. 10 is a photographic reproduction of a sample of one formof high-loft, nonwoven material made in accordance with the method of the present invention;

FIGS. 11 and 12, respectively, are enlarged photographic reproductions of transverse and longitudinal sectional views of the material shown in FIG .10;

FIGS. 13-22, respectively, are photographic reproductions illustrating other samples of material made in accordance with the method of the present invention;

FIG. 23 is a fragmentary plan view of a sample of a fabric product embodying the present invention;

FIGS. 24-27 illustrate, in plan view, exemplary alternative adhesive patterns that may be used for the base web in practicing the method of the present invention;

FIGS. 28a and 28b comprise fragmentary portions of a schematic view, in side elevation, of exemplaryI apparatus which may be employed to form laminated, highloft, nonwoven fabrics in accordance with the present invention;

FIG. 29 is a fragmentary perspective view of an exemplary two-ply, laminated, high-loft, nonwoven fabric made in accordance with the present invention, here of a schematic view, in side elevation, of exemplary apparatus which may be employed to shear a high-loft, nonwoven fabric made in accordance with the present invention to form a fabric having a cut-pile surface;

FIG. 32 is a greatly enlarged, simplified and somewhat exaggerated sectional view similar to FIG. 4, here illustrating in schematic form a high-loft, nonwoven fabric having a cut-pile surface wherein the fabric is formed utilizing an adhesive pattern of the types shown in FIGS. 2 and 8, or in FIG. 24; and, 1

FIG. 33 is a greatly enlarged, simplified and somewhat exaggerated sectional view similar to FIG. 32, here illustrating in schematic form a high-loft, nonwoven fabric having a cut-pile surface wherein the fabric is formed utilizing an adhesive pattern of the types shown in FIGS. 25-27.

While the invention is susceptible of various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as expressed in the appended claims. l

THE ENVIRONMENT OF THE INVENTION In practicing the method of the present invention in its preferred form, a base web of fibers is first prepared and embedded at spaced points on the fibers in a layer of adhesive. The layer of adhesive may be in the form of an open adhesive pattern applied to one side of the web, or as disclosed in greater detail in aforesaid Ser. No. 856,793, now U.S. Pat. No. 3,720,554, it may be in the form of a pattern of adhesive which has been smeared to provide a continuous layer of adhesive in which the fibers or elements are embedded at spaced points on'the elements. Different procedures have been used in pre'- paring the base web. For example, textile length fibers may be processed through conventional cotton card machinery to produce a carded web for the base web. [In such a carded web 50% to 70% of the fibers may be oriented substantially parallel with the machine direction. It has been found, however, that the most uniform product has been obtained with the method of the pre's'ent invention by using base webs having a higher percentage of the fibers alined with the machine direction such, merely by way of example, as a highly drafted web in which, as a result of the drafting process, to 95% of the fibers may be alined with the4 machine direction. Such webs of bonded, highly drafted fibers, of course, have substantial utility in themselves and are the sub ject, forfexample, of the aforesaid copending application, Ser. No. 79,287 and U.S. Pat. No. 3,553,065. The present invention, however, goes far beyond the preparation of an adhesively bonded carded web or the products and methods disclosed in those two applications, and results in the formation of a high-loft, nonwoven fabric having significantly different characteristics than the nonwoven web utilized as the basematerial.

Broadly stated, the method of the present invention in- Ivolves taking the base material and performing the subsequent steps of (l) activating to a softened, tacky plastic state the layer of adhesive in which the fibers" are embedded; and (2) gathering the softened adhesive layer andthereby consolidating the adhesive into a substantially continuous backing layer, while (3) simultaneously looping the portions of the fibers between the spaced points of embedment outwardly from the backing layer formed by the gathered, consolidated adhesive. The resulting product is characterized by the high-loft or deep pile of the loops of fibers which extend outwardly from the substantially continuous, nonuniforrn adhesive backing. The particular depth of pile or degree of loft of the loops, of

the adhesive backing layer; .laminatingthe high-loft, nonwoven fabric to an additional backing layer'or layers; and/ or blending together fibers of different `c'olors'or other characteristics in the base web in order to achieve color patterns or different surface textures and appearances .in the final product.These additional steps will also -be discussed below, following the detailed description ofthe over-all method taken in connection with the drawings.

Turning now to the drawings, FIG. 1 v'schematically illustrates an exemplary apparatus for performing" the method of the present invention. This apparatus includes a web forming ksection and an adhesive compacting and vfiber looping section 30. The web forming section 10 sgenerally similar to the apparatus'disclosed in the aforesaid copending application, Ser. No. 79,287, with certain modifications as disclosed Vin the aforesaid U.S. Pat. No. 3,553,065 but it is here shown in more complete and fvisible form than shown in either of those disclosures. It will be appreciated as the ensuing description proceeds, that fiber webs made in accordance with the method disclosed in the aforesaid copending application, Ser. No. 79,287, are also usable with the subsequent method steps of the present invention, as are carded webs and webs prepared by other processes. f i

As shownl in FIG. l, multiple slivers 11 of textile fibers are drawn from their respective supply cans (not shown) into a draw frame 12 which comprises a series of pairs of grooved rolls 13; the rolls lof each pair being driven by appropriate gearing (not shown, but well known in the art) at a peripheral rate of speed somewhat faster than the rate of operation of the preceding pair. -Merely by way of example, the pairs of rolls 13A may be adjusted to provide any over-all increase in speed and, therefore, an extent of ber draw on the order ofv11 through the draw frame 12. As the juxtaposed slivers pass through draw frame 12, the individual fibers are drafted and spread out to form a flat,v striated web of substantially alined fibers as shown at 14. Web 14 Vis maintained adjacent av supporting conveyor sheet 15 on the surface of which adhesive has been previously applied in a preselected pattern. v

. In.this embodiment, the conveyor sheet 15 -comprises an endless conveyor lbelt treated on atl least. its upper surface with a release agent. vOne example of such a belt comprises Woven glass fiber with 'a surface coating of tetrafluoroethylene resin. Other examples of release coatings are well known, and comprise such materials as silicones, fatty acid metal complexes, certain acrylic polymers, and the like. Heat resistant lir'is or thin metal sheets treated with release agents may also be used as the: carriersheet. W i i Prior to the time the web 14 is picked upby the belt 15, the latter has imprinted on its release-treated surface a pattern of flexible, thermoplasticV adhesive such yas` is shown at `16 in FIG. 2. It will be `understood that, as shown in FIG. l, the adhesive is actually on the underside of belt 15 which"becomes the upper surface-after passing aroundv roll 17,at which time the adhesive pattern 16 directly contacts the fiber web 14. The pattern isishown as being'visible'in FIG. 2 only for illustrative purposes;

i, .The belt 15 is fed around roll"17 at a speed slightly' inV excess of ,the delivery's'p'eed offthiefiialpair of rolls 13 of drawv frame. 12 in order'vto, maintain web 14 under slight tension, wherebytheindividual highly-drafted fibers are retained in their alined' and tensioned condition. Drive rolls 18, 19 are rotated (by suitable drive means, not shown) to drive belt 15 at a speed sufficient to maintain the proper "tension on the web 14.

.In the method shown for applying adhesive, the belt 15is fedthrough a nip formed between a printing roll 20 and a back-up roll 21 maintained in very light pressure engagement therewith. The surface of printing roll 20 is provided with an intaglio pattern to which adhesive may be supplied in various ways well known to those skilled in the art. For example, in the aforesaid parent application, Ser. No. 769,959, now abandoned, a system is schematically disclosed'wherein the lower portion of the printing roll 20 picks up adhesive directly from a dip pan, with excess adhesive being removed by a doctor blade, thus leaving only the intaglio patterned surface filled. However, in the practice of the present invention, it has been found that more satisfactory results are obtained by pumping or otherwise transferring adhesive 22 from a supply pan 23 to a reservoir located immediately above an inclined doctor `blade 24.--the reservoir being defined in part by the upper surface of the inclined doctor blade and the adjacent portion of the rotating peripheral surface of the printing roll 20. Thus, as the printing roll 20 rotates (in a counterclockwise direction as viewed in FIG. l), the intaglio patterned surface thereof is filled with adhesive 22, excess adhesive is removed by the doctor blade 24, and a metered amount of adhesive is then transferred to the underside of release coated belt 15 in a preselected patern forming a discontinuous layer. The pattern shown in FIG. 2 is in the form of an open diamond pattern of adhesive.

The particular form of the adhesive layer or dimensions of the intaglio pattern employed and, indeed, whether the layer is continuous or discontinuous are not critical to the practice of the invention in its broadest aspects. Thus, it has been found that a continuous layer of adhesive may be used as disclosed for example in the aforesaid application 856,793, now U.S. Pat. No. 3,720,554, provided that the fibers are embedded therein at spaced points. Alternatively, patterns other than the illustrative diamond pattern hereinabove referred to can be utilized, and certain of such patterns will be subsequently described in connection with FIGS. 24-27. For illustrative purposes, however, it is noted that vexcellent results have been achieved where a diamond pattern was employed in which adjacent lines of adhesive were spaced apart in both directions by 1A, and wherein the intaglio printing roll 20 had'adhesive cells or lines 0.007 deep and `0.025"wide.y

Since the surface of belt 15 is treated with a release coating, the adhesive remains substantially on the-surface with no penetration therein and is preferably `in a somewhat tacky condition. The printed belt is drawn from the printing nip around roll 17 positioned closely adjacent the output end of draw frame 12 and, as statedfabove, at a speed slightly in excess of the delivery speed of the last two rolls in the draw frame. The web 14 emergingv from the draw frame 12 is deposited on the tacky adhesive "116 on belt 15 and held in tensioned engagement therewith by the adhesive and the above-mentioned speedl differential. This continuous tension prevents the fibers in the web from losing their highly-drafted andalined condition.

y In practicing the method of the present invention, 'additional alined and highly-drafted fibers mayy be addedto the web 14 on the adhesively printed belt 15. Por this purpose.. a second draw frame 25 similar to the draw frame 12 is provided to draw additional slivers 26 of fibers vfrom their supply cans (not shown) and, after draftingaandalining them, to deposit the fibers on the moving web 14 carried by the belt 15. In such cases, Athe amount of adhesive printed on the belt' 15 may. be increased to insure that some of the adhesive in the adhesive pattern 16 penetrates the fibers of web 14 drawn from the draw'frame 12 and reaches the fibers drawn from slivers 26 which pass through the second draw frame 25. The arrangement is such that the adhesive contact between the fibers drawn from slivers 26 and the pattern 16, together with the speed differential of the belt 15 relative to the last pair of rolls in the draw frame 25, maintains the fibers drawn from slivers 26 under slight tension, whereby they also maintain their highlydrafted and alined condition.

It is another aspect of the present invention that the fibers deposited on the web 14 from draw frames 12 and 25 need not be the same kind, size, color or quantity. Nor, for that matter, do the fibers of the slivers l11 and 26 need to be uniform in these respects as they are drawn into the draw frames 12 and 25. Thus, various blends of fiber sizes, kinds, colors and quantities can be deposited across the web 14 from each of the draw frames 12 and 25 and in various combinations of first and second layers of fibers. Additmal draw frames can also be employed if desired.

Further in keeping with the present invention, the fibers from each of the draw frames 12 and 25 pass under respective bars 27 and 28 before being deposited on the belt 15. The bars 27, 28 may be oscillated in a direction generally transverse to the movement of the web 14 and, preferably, provision is also made for controlling the frequency and amplitude of the oscillation of one bar relative to the other. Thus, as each bar is oscillated, the fibers deposited from the respective draw frames 12 and 25 take on a generally sinusoidal or sawtooth wave pattern of controlled frequency and amplitude. A simple, but somewhat similar, oscillating bar arrangement is disclosed in the aforesaid U.S. Pat. No. 3,553,065. However, the single bar arrangement there disclosed did not afford, nor even contemplate, the significantly improved attributes made possible by the present invention.

An example of the web 14 formed on the illustrative apparatus (FIG. l) is shown in FIG. 2. As previously mentioned, a series of parallel and diagonally disposed lines of adhesive are printed in criss-cross fashion on the belt to form a pattern 16 of adhesive having substantially open spaces in the configuration of diamonds. In depositing the fibers from the first draw frame 12, the bar 27 was not, in this instance, oscillated. Thus, the fibers making up the first component I14a of the web 14 are substantially all alined in the direction of web movement. The fibers making up the second component-14b of the web, however, will be seen to be deposited in a generally wavy or saw-tooth pattern as a result of oscillation of the bar 28 associated with the second draw frame 25, thus altering the appearance characteristics of the finished fabric. In addition, oscillation of the bars 27 and/or 28 serves to alter the structural and functional characteristics of the fabric in that a controllable percentage of the fibers may be deposited on the open adhesive pattern at an angle to the machine direction. It has been found that such fibers do not interfere to any significant extent with the subsequent fiber looping steps of the present invention. Moreover, it is believed that the presence of such fibers extending at an angle to the machine direction serves to increase the cross-directional strength of the fabric being produced by actually increasing the number of oriented fibers which extend partially .in the fabric cross-direction. Preferably, in the practice of this aspect of the present invention, when both bars 27 and 28 are oscillated they are oscillated in out-ofphase relation to one another so as to cause fibers in one web component 14a to cross fibers in the other web cornponent 14b at even greater angles while simultaneously maintaining the fibers Vin a highly oriented state. It will, of course, be understood that the phase and amplitude of the oscillated fiber pattern may be selectively adjusted and controlled to provide a controlled angular deposition of fibers on the open adhesive pattern 116, thus enabling control of the cross-directional strength character-` istics of the fabric resulting from fiber oscillation. This will, of course, vary dependent upon various other parameters such, for example, as the type of fibers employed, the type of adhesive employed, fiber-adhesive ratios, gathering ratios, and indeed, the particular end use to which the fabric is to be put. Consequently, in many instances it may not be desirable to oscillate either bar 27 or 28. It should be appreciated, of course, that EIG. 2 is only intended to be illustrative and, while the lines representing the fibers for both components 14a and 14b are spaced apart for clarity, in practice the highly-drafted fibers of both component are very close to one another.

Also for illustrative purposes, it will be noted that web component 14b has three bands of fibers designated color. These bands of fibers may be the same or different colors; but, in any event, they differ from the color of the balance of the bers of web component 14b. Further, as previously mentioned, the fibers of web component 14b may differ from those of component 14a in kind, size, color or quantity depending upon the desired color pattern and surface characteristics of the final product, as more specifically described below.

Following deposit of web components 14a and 14b on the adhesive printed belt 15, the belt is drawn around a heated curing drum 29 where fusing and curing of the adhesive is substantially completed while the web 14 is maintained in firm contact therewith to bond the individual fibers. To insure effective heating and fusing of the adhesive, it is desirable that travel of the combined belt and web be around a substantial portion of the drum 29. In the illustrated embodiment, a fly roll 29a is positioned to apply tension on the combined belt and web as they travel around the drum 29 to insure complete embodiment of the fibers in the adhesive. The fibers of the web 14 are thus bonded together while retaining their highly-drafted and substantially alined condition in the particular pattern in which they were deposited on the open pattern of adhesive 16 printed on the belt 15.

After leaving the fly roll 29a, the combined web 14 and belt 15 are preferably passed over the drive roll 19, which also serves as a cooling drum, to set the adhesive. The bonded web 14 is stripped from the release-coated surface of the belt 15 by the guide roll 31 as the web leaves the cooling drum 19. 0 While various `well-known adhesives may be employed in the foregoing process, advantages reside in the use of plastisols, which are colloidal dispersions of synthetic resins in a suitable organic ester plasticizer, and which, under the influence of heat, provide good binding power while remaining soft and flexible. While many adhesives of this type are known, those found particularly useful for incorporation in the product of this invention include vinyl chloride polymers, and copolymers of vinyl chloride with other vinyl resins, Aplasticized by organic phthalates, sebacates, or adipates. These provide a fast curing plastisol adhesive characterized by relatively low viscosity, low migration tendencies, and minimum volatility. Such adhesives remain flexible after curing, and can be activated to a softened, tacky plastic state by subsequent heating.

It has been found that other adhesives may be employed in the process-for example, organisols utilizing resins such as the vinyl chloride polymers and copolymers. Furthermore, still other adhesives may be employed provided that they satisfy specified characteristics in the base web produced in the web forming section 10, and in the finished fabric produced in the adhesive compacting and fiber looping section 30 (FIG. 1). In general, such adhesives should be applied to the base web by procedures which will not disarrange the fibrous structure of the web; such adhesives should heat-set at temperatures below the degradation temperature of the fibers in the base web 14 to secure bonding of the fibers to the adhesive; such adhesives should be reactivatable in the subsequent adhesive gathering and consolidation stage of the process; and such adhesives should form a flexible back- 9` ing layer for the finished fabric and should strongly bond the berloops in place. For example, emulsions of ther# moplastic resins such as acrylics and rubberlike compounds, illustratively ABS, have the requisite properties to serve'as the bonding adhesive for the web 14.

In carrying out the present invention, the base material, made as heretofore described and comprising a web 14 of highly-drafted fibers embedded in adhesive herein shown in an' open pattern, is fed into the adhesive gathering-consolidating and fiber looping section 30 of the apparatus shown in FIG. 1. As shown here, thefweb 14 continuesdirectly from the web forming section to the consolidating and looping section 30. It should be 'appreciated,`however, that the web 14 discharged from section 10 could be rolled up for storage or transport and then subsequently unrolled and fed' into section 30. Also, as previously mentioned, other webs such, merely by way of example, as those made in accordance withthe methods disclosed in the aforesaid copending application, Ser. No. 79,287 and U.S."Pat. No. 3,553,065," can be further processed in section 30 in keepingwith the method of the present invention.

As-illustrated in FIG. 1, the web 14, while still under tension, is fed around an idler roll 32 and on to the surface' of a heated forming drum 37. In its preferred emlIt will, of course, be understood that while looping of `liber portion P is occurring, additional adhesive points C-D, etc., travelling around the drum 37 impinge against the gathering blade edge 39 causing a consolidation of these adhesive points and looping of their intermediate ber portions P1 as is also indicated in FIG. 9. This occurs simultaneously at all points across the web at the blade edge, producing a substantially continuous backing layer of'adhe'sive from which extends the multiplicity of loops formed by the fibers of the base web. The thus formed substantially consolidated layer of adhesive is carried bodiment, the drum 37 is made of metal with a highly polished, chromium plated surface which is heated and maintained at a temperature of approximately 250 F. Also, the web 14 is arranged to travel a substantial distance around the drum 37 with the adhesive 16 in contact with the heated drum surface. As the web 14 is fed onto web 14 of fibers and softened, tacky adhesive isreformed by the cooperative action of the drum 37 and a gathering blade 38 having a flat edge 39. The blade edge-'39 operates'to gather or consolidate the adhesive 16 into a substantially" continuous backing layer of adhesive, while simultaneously outwardly looping the fibers of thefweb between the points of their embedment spanning'theopen spaces in the original adhesive pattern. Thereformed and consolidated material 40 then leaves lthe blade edge 39 and moves ontova at take-olf `surface 41 and a discharge conveyor 52.-

Turning now to FIGS. 7-9, the method of making the novell high-loft, nonwoven fabric 40 of the present inventionwill be explained in greater 'detail in connectionwith anillustrative sequence of the gathering and looping oft-a single fiber of the web 14 andthe consolidation of its two 'original'points of adhesive attachment' in the adhesive'16.

As seen in FIGLS, the fiber has a-portion P which'extends across the" open space of the diamond pattern of adhesive 16 -frornpoint' A to point B where it is embeddedin the adhesive. Referring to FIG. 7, the series of" views in this Figure illustrates how the rportion P of the fiber is formed into a loop; viz., when point A being carried around the heated drum 37 impinges against the vgathering blade edge 39, `,its forward motion is halted and it .is scrapedalong the surface of the drum, whilepointB continues'toA advance with the drnmsurfacey since, dueto its softened and tacky condition, it adheres to the smooth drumvsurface. Aspoint B advances relative to point-.,A, the` portion P of thev fiber between points A and B is caused to bow outwardly from the drum surface; Finally, point B overtakes point A and these points of adhesive ar`subst`an'tially consolidated as seen in" FIG. 9. In the meantime, ber portion P has' been looped outwardly from the drum surface. Y

away from the blade edge 39 along the take-olf surface 41 and provides a substantially continuous backing layer for the outwardly looped fibers, thus producing the fabric 40.

While in the preferred form of the invention disclosed andl claimed herein, it is desired to achieve substantially complete consolidation of the adhesive into a continuous backing layer, in practice it has been found that the degree of consolidation varies randomly throughout the substantially continuous backing and, therefore, it is possible to draw the fabric slightly, thus producing a substantially continuous adhesive backing layer with random openings therethrough. Since complete consolidation, while desirable, is not necessarily attained in the practice of the broadest aspects of the present invention, the degree of consolidation is defined herein, and in the appended claims, in terms such as to consolidate the open adhesive pattern into a substantially continuous adhesive layer. Thus, those skilled in the art will appreciate that terms such as consolidate and gather as used herein and in the appended claims are intended to connote an arrangement for consolidating, gathering or compacting the adhesive into a substantially continuous adhesive backing layer-albeit that such substantially continuous backing will be nonuniform in thickness and may have, and often will have, small random fissures and gaps thereinall Vv'as distinguished from the arrangement disclosed in the aforesaid copending application, Ser. No. 820,224, now U.S. Pat. No. 3,687,754, wherein an open adhesive pattern is only partially consolidated to minimize bonding of adjacent lines of adhesive and thus form a discontinuousadhesive backing layer characterized by its elasticity vand/ or stretchability.

p Another important feature of the-invention is that not only does each fiber portion P loop outwardly from the drum surface but, also, as the loop is formed it turns, reaching, a position vin the fabric 40 generally perpendicular to the directionV of the original alinement of fiber portionP. Thus, the fiber loops arrangethemselves so that the plane of each'lop is substantially normal to the original liber alinement shown in FIG. 8. The reason for the loop twisting as it is formed may be explained by this observation. If two spaced points of a single fiber not in a web are brought together, it has been observed that the fiber willform a loop and, as the loop is formed, it twists towards a position'of minimum internal stress, turning through an langle which tends to approach In carry'- ingn't the method of the invention, because of the great 'number of libers in the web and their proximity one to lanother,feach ber loop engages the neighboring liber loopswith` the resultv that all the loops are blocked from turningbeyond the plane substantially normal to the machine direction, and are constrained in thaty position by the interference between the loops. In' practice, of course, the actual direction and degree of loop -twist depend upon the characteristics of the fibers in the original'web 14. The arrangement of the loops normal to the machine `direction is clearly evidenced by reference to FIG. ll, which is a reproduction of an "enlargedphotograph' of'a transverse sectional view of the fabric shown in FIG. 10, made in accordancewith themethod of the invention. The ber loops andy their attachment to the adhesive layer appear Lin' FIG; 11, while in FIG. 12, vwhich is a sectional view taken parallel to the machine direction and, thus, at right angles'fto-FIG. 11,'fthe ber loops are viewed from ltheir' :11 edge and, for the main part, are not discernible in this view as loops.

It is important to note, however, that throughout the fabric the heights of the fiber loops vary according to the spacing between the points of attachment of each fiber to the adhesive pattern in the base web. Referring to FIGS. 4, 8 and 9, it will be seen, for example, that the loop formed bythe fiber portion P1 between the points of adhesive attachment C, D will have a lower height than the loop formed by the longer fiber portion P between the points A, B. On the other hand, however, successive loops in adjacent diamonds, when viewed in a vertical section taken along the machine direction (FIG. 5), will have the same height since the liber length P will remain the same between successive sets of points A, B. This results in a dense fabric with the lower loops supporting and filling around the higher loops and the top surface of the fabric being formed by the tops of the higher loops.

The appearance of a fabric so constructed depends not only on the height of the fiber loops but, also, on the type and denier of the fiber used in the base web, and one of the features of the invention is that the depth of the fabric and the evenness of the surface may be varied by adjusting selected ones of the control parameters, as will be explained below. In general, it may be said that for both relatively low and moderate height high-loft materials which have been produced with the method of this invention, the fabric appears to have a uniform thickness with a somewhat uneven surface texture. With very deep highloft fabrics, particularly those made from exible, low denier fibers, the higher loops tend to lay one over the other, thus providing a very soft, napped, fuzzy, fibrous surface. For usages where a more uniform surface texture is desired, moderate height and deep high-loft fabrics made according to this invention may be shorn at some intermediate height as hereinafter explained in greater detail. In such cases, a higher percentage of the fibers will extend outwardly from the backing layer fully to the finished surface of the fabric and the fabric then has a cut-pile appearance.

The following three specific examples of fabrics made by carrying out the method of this invention illustrate the effect of varying one of the control parameters; in this case, the angle of the edge of the blade 38 relative to the drum 37. Referring to FIG. `6, it will be seen that the blade edge 39 forms an angle a with the line T tangent to the surface of the drum 37. It has been found that the blade edge angle a is one parameter that determines the depth of the fabric produced and the degree of uniformity of consolidation of the adhesive backing layer.

As a result of trying different blade angles, it has been determined that the preferred blade edge angle a when dealing with adhesive patterns having lines of adhesives spaced approximately 1A" apart is between about 17 and solidated adhesive backing layer. This appears to be the result of insufficient relief between the blade edge and the drum surface for the fabric to fiow evenly and smoothly off the drum surface as the result of the action of the blade, which produces varying degrees of consolidation of the adhesive and a non-uniform layer with fissures and gaps and scattered areas wherethe looping is irregular, tending to spoil the surface appearance of the fabric. With blades having edge angles a substantially above 34, both the problem of non-uniform adhesive consolidation and poor loop formation has been experienced. There is also a tendency as the angle a of the blade edge is increased substantially above 34 for the fabric to be formed with pronounced ridges, which may be undesirable in the finished product.

Now turning to the three Examples I-III, the base web was made from 3 staple length, rayon 40 fiber and had a weight as it came olf the curing drum 29 of 14 grams/ sq. yd. This weight was made up of 7 grams of fiber and 7 grams of adhesive in the base web material. The adhesive was applied in diagonal lines 1A apart in both directions forming a diamond pattern in which the lines of adhesive were approximately 0.004 deep and 0.025 wide. In the first stage of forming the base web 14, the curing drum 29 was operated at 300 F. and at a surface speed of 24 ft./minute. The base web 14 was thus carried at 24 ft./minute lineal speed to the heating drum 37 which was operated at 250 F., and around the drum to the gathering blade 38. The lip of the take-away surface 41 was positioned tight against the blade edge and less than 1&2" below the corner of the blade edge.

For the purpose of comparing the effect of using blades with different edge angles a, Example I is a fabric produced using a blade with an edge angle a of 17 and, thus, within the preferred range; Example II is a fabric produced using a blade with an edge angle a of 9 and, thus, below the preferred range; and Example III is a fabric produced using a blade having an edge angle a of 74, and thus above the preferred range.

EXAMPLE I FIG. 13 is an enlargement of a photograph taken of the front surface of the fabric to show the surface of the fabric in plan view; the machine direction of the fabric is not indicated but is vertical on the sheet. Many of the loops are clearly visible, as is their orientation generally normal to the machine direction.

FIG. 14 is an enlargement of a photograph taken of the back of the fabric to show in plan view the exposed surface of the adhesive layer; the machine direction is again not indicated but is similar to FIG. 13. Although a number of fissures or gaps show in the backing layer, the size of these is magnified in the figure and, to the eye, the adhesive layer is substantially uniform and interrupted only by occasional fissures or gaps of up to JAG" across. In making the fabric of Example I, the take-away speed of the fabric from the blade 38, which is determined by the speed at which the conveyor 52 is operated, was about 2 ft./minute such that the ratio of surface speed of the heating drum 37 to take-away speed of the fabric was about 12:1. By operating the process with a higher ratio up to 15: 1, it has been observed that more uniform adhesive consolidation is obtained, while by operating at a slightly lower ratio, i.e., 10: 1, somewhat less uniform adhesive consolidation is obtained. By varying this control parameter, therefore, desired adhesive layer characteristics can be obtained.

The weight of the fabric varies in direct proportion to the take-away ratio (assuming the same base web weight). Thus, with a take-away ratio of 12:1 and a 14 gram/sq. yd. base web, the finished fabric will have a weight of about 168 grams/sq. yd.

EXAMPLE II The fabric evidences the effect of reducing the angle a of the blade edge such that the small relief angle between the blade edge 39 and the drum 37 interferes with the smooth ow of fabric 40 over the blade 38. As shown in FIG. 15, which is an enlargement of a photograph of the front surface of the fabric to display it in plan view, the

f fiber loops are formed irregularly or the fibers are formed v13 of the fabric of Example I (FIG. 14). These fissures or 'gapsff'(`rangin'g"o'n the order' of /llg" across) in the adhesive layer as shown in the rphotograph may in some cases be 'substantially wider (up to 1/2"') and, with the irregular loop formatioiron the's'urface of the material, represent imperfectionswhich mayrnake the fabric unsuitable for those specilifiusages where uniformity in appearance and structure Iare critical. However, this fabric has a high loft andregular loop'forn'iation throughout a large percentage 'ff its total Fareafand may, jtherefore, have utility for less rcritical applications.v

EXAMPLE III 'FIGz' 17 is'an enlargement ofa photograph of the front 'surface of` the fabric made, as 'previously noted, by em- .ploying ',a-:blade having anedge angle a of 74. Pronounced ridges Atransverse to the machine direction are produced' as the fabric 40 comes off the blade 38 onto -tlie take-away surface 41 at amore 'rapid rate than the conveyor 52 yremoves it therefrom. The fabric alternately builds'up in ridges adjacent the blade and is removed by the conveyor. During the periods when the fabric builds .up to form' ridges adjacent'the blade, the loops tend to .beformed regularly and, since the adhesive layer is still fatfthatp'oint vsoft and tacky, the inside facing surfaces of the-ridges stick 'to each other. During periods when the fabric is 'removed by the conveyor away from the blade, the loop formation tends to be irregular and, thus, as ishownl in FIG. 18, the loft of the material between the Y'ridges is less,'the .loops are more irregular, and their mass is less. InlFIG. 18,' which is an enlargement of the back side` of the -fabric shown in FIG. 17, transverse lines defining the bottom of the ridges are clea'rly visible. Because :of the`pronounced ridges, the bulk of the fabric is considerably greater than the fabrics of Examples I and II where measured to the tops of the ridges in the fabric. This material has utility for applicationswhere bulk is desired, such as insulation, even though it does not have ythe uniformity of appearance and structure of Example I (FIGS. 13 and 14).

practicing the method of the present invention and, las evidencedby the foregoing Examples I-III, it'has been fouridthatuoneof the major factors affecting the thickness o the yfabric is the loop height as determined* and limited by 'thes'pacing between points of fiber adhesive attachment '1A-B, C-D, etc."(FIG.` 8). To obtain the maximum thicknessir of fabric vwith a given adhesive pattern, the blade edge angle otfs'hould be" such as to produce not only sufficient consolidation of the adhesive layer to provide good fiber `aitltaifzhrnent throughoutthe 'fabric but, also, sufiicient con- 'solidatin to insure the production of a maximum number 'of 'full height fiber loops. Thus,"'as the blade edge Vangle a `increases,"the condition is approached where thek web is being skived off thefroll rather'than being consolidated gathered. The fabrics produced with higher blade edge angles-tlhave reduced'adhe'sive consolidation and fabric thickness ""becau'se fewer loops reach their maximum height. .Ihis'eifect is noticeable in the regions between the ridges oflt'h'e fabric of Example IIIA (FIGS. 17 and '18) fir/fiere the loops are less deep than inthe material of either E ampie' runes; 13 and` 14) orr Example 1v1` (FIGS. Y

InA carrying out the method of the invention using a blade'38'having ian" edge ``angle et within the preferred ange,j' it hasbeen foundv that'tliejfabric loft may be regu- I' by changing the machinevdirection dimension of dlyresiveV pattern. Thus, byV increasing this'dimen` theheightV of the loops may be increased, thereby asing thefabric loft. Larger diameter fibers, strands, or-'yarns mayl` also -be "used asv the elements of the base brui gathering blade.` as, and sufrirerit adhesive lmust l web toproduce heavier, carpet-like finished fabrics. The

be present to provide a substantially continuous backing layer of sufficient thickness to obtain strong attachment of the loops in the finished fabric. More specific disclosures of types of adhesive patterns suitable for use in making carpet-like fabrics of larger diameter fibers, strands, or yarns may be found in the aforesaid copending application of Robert l. Stumpf Ser. No. 856,793, now U.S. Pat. No. 3,720,554, and the aforesaid copendingapplication of Herman G. Minshell, Robert I. Stumpf and William J. Mattes, Ser. No. 77,840, now U.S. Pat. No. 3,729,353, both of which are assigned to the assignee of the present invention.

Now turning to a consideration of a different control parameter-vz'z., the location of the take-away surface 41the preferred location of the take-away surface is, as shown in the extreme right-hand view in FIG. 7, tight against the blade 38 and even with the outside corner 39 of the blade. With the surface 41 in this preferred location, the fabric photographically depicted in FIGS. 10, 1l and l2 was produced. This fabric has a moderately even surface texture and a dense mass of loops for-ming a deep, high-loft pile. It was produced from a base web similar to the base web used for the preparation of the fabric Examples I-III; viz., a highly drafted web of rayon 40 fibers having a weight of approximately 14 grams/sq. yd. The blade edge angle a was 17 (i.e., within the preferred range), and a slow rate of removal of the fabric from the blade edge 39 was used such that the take-away ratio was greater than 15:1 and provided a highly consolidated adhesive backing layer and uniform depth of fabric.

It has been found that by lowering the take-away surf face 41 a distance Y (FIG. 7) from its preferred location, the structure of the fabric will be drastically affected. Referring to fabric Examples 1`V (FIGS. 19 and 20) and V (FIGS. 21 and 22), these Examples show that the bulk of the fabric may be increased substantially by lowering the take-away surface 41. The effect of lowering the surface is somewhat similar to the effect from using a blade 38 with an edge angle a substantially above the preferred range in that pronounced ridges are also produced in the fabric, thereby increasing its bulk. But, whereas in fabric Example III (FIGS. 17 and 18) the fabric is distinctly thinner between the ridges, in fabric ExamplesIV and V produced with a lowered take-away surface 41, the thickness of the pile between ridges remains uniformly deep and a much bulkier material is produced. The amount that the take-away surface is lowered does clearly affect the degree of bulking, and it is apparently the case that as the distance Y increases, the fabric bulk increases.

EXAMPLE 1V Referring to FIG. 19, the fabric illustrated in top plan view in this photographic reproduction is made from a base web 14 of rayon 40 fibers similar to that used for preparing fabric Examples I-III. The location of the takeaway surface was lowered a distance Y (FIG. 7) -of approximately 5A; inches and the fabric produced has 21/2 to 3 ridges/inch and a Weight of approximately 590 grams/sq. yd. As shown in FIG. 20, which is a plan view of the underside or back of the fabric, the bottoms of the ridges or pleats are clearly defined by transverse lines. Lowering the take-away surface 41 causes the fabric as it flows from the blade edge 39 to drop down to the take-away surface and collect there in'deep folds or 'f' from the'adjacent pleats in the finished material.

pleats before it is removed by the action of the con'veyor 52. In FIG. 19 the ber loops are clearly evident. This material has, of course, transverse ridges throughout its length and they are clearly defined and distinguishable The surface of the fabric is soft and fuzzy.

The foregoing Examples I-IV illustrate the effect of varying two `of the control parameters-viz., the blade edgeangle a and the position of the take-away surface 41-both of which directly affect fiber looping and adhesive consolidation at the blade edge 39 due to the gathering function that the blade 38 performs. A further related parameter that affects the gathering function of the blade is the take-away speed of the fabric from the blade edge. With blade 38 having an edge angle ot within the preferred range, and a take-away surface at the preferred location, the take-away speed is desirably regulated to remove the newly formed fabric at the rate at which it is being formed, and it has been found that under these conditions the normal ratio of the surface speed of the heating drum 37 to the take-away speed will be about 12:1. By increasing the ratio up to, for example, 15:1, by slowing down the fabric take-away speed, more uniform adhesive consolidation has been obtained while the mass of the fiber loops is made somewhat more dense, so that a fabric with a higher weight has been produced. By increasing the fabric take-away speed, such that the fabric is not allowed to gather at the blade edge 39, the fabric will be drawn or extended while the adhesive layer is still in a plastic condition, thereby opening the adhesive layer, thinning the fabric pile, and reducing the weight of the finished material.

As illustrative of the effect of lowering the take-away speed and thereby increasing the take-away ratio, a fabric having high weight and bulk was made as set forth in the following Example.

EXAMPLE V The fabric of this Example, shown in top plan view by the photographic reproduction appearing in FIG. 2l, was formed by using a take-away surface dropped 7A; inches below the preferred location (Y=% inches) and by reducing the take-away speed of the finished fabric. This produced a pleated, bulky fabric. The folds or pleats have less height than in the fabric of Example IV and are less frequent, occurring approximately 11/2 ridges/ inch. The fewer pleats per increment of length is a result of lowering the take-away speed even though the takeaway surface was lower than in the previous Example IV. But this fabric has a particularly deep loft and an extremely fleece-like surface with the loops of fibers having maximum height. The nap is deep, the surface is fluffy and soft, and the fibers are less securely attached to each other and to the adhesive layer than in the case of Example IV. The soft, fluffy material has a weight of 890 grams/sq. yd.

As shown in FIG. 22, which photographically illustrates this material from the underside, the lowering of the takeaway surface 41 has not interfered with obtaining a substantially uniformly consolidated adhesive backing layer. In this case the adhesive layer is shown to be interrupted by the ridges but, otherwise, it is a substantially solid consolidated backing layer.

Certain of the foregoing Examples-viz., Examples III, IV and V-illustrate certain adjustments in parameters which may be made to achieve various forms of corrugations or ridges in the finished fabric. Example III (FIGS. 17 and 18) illustrates the production of a corrugated fabric by increasing the blade edge angle a which results in a somewhat irregular loop formation and a high bulk material. Example IV (FIGS. 19 and 20) illustrates a fabric with regular loop formation and high bulk due to corrugations produced as a consequence of lowering the take-away surface. Example V (FIGS. 21 and 22) demonstrates that as the take-away speed is reduced, fewer corrugations will be produced even where the take-away surface is lowered, but the fabric has high bulk and weight.

It will thus be seen that by selection of the blade edge angle a, take-away ratio, and the height of the take-away surface 41, the fiber looping, fabric pleating plus bulk and basis weight of the fabric may be controlled to produce a product of desired characteristics.

Further parameters that affect adhesive consolidation 75 and fiber looping at the blade edge 39 are: (l) the adhesive pattern applied to the fibers in the formation of the base web 14; (2) the adhesive weight as a percentage of the weight of the web; (3) and the area of the web covered by the adhesive pattern. The adhesive lwas applied in the preparation of Examples I-V in the form of diagonal lines, criss-crossed, to provide an open diamond pattern with the size of the opening in the diamond in the machine direction being less than the lengths of the lfibers used for the base webs. Thus, where rayon 40 was used, with liber lengths from 1/2 inches to 3 inches, a 1A inch diamond pattern applying adhesive to 20% to 25% of the total web surface was found effective.

Other adhesive patterns which may be used include unevenly spaced lines of application, such as criss-crossed sine Waves as shown in FIG. 24. The spacing of such lines of adhesive may furthermore be increased or decreased to change the maximum height of the element loops and, thus, the depth and surface texture of the finished material.

When criss-crossed lines of adhesive are used, the loops of the fabric will have varying heights due to the different spacings of the points of attachment (A-B, C-D-FIG. 8) of the base web elements to the adhesive. To produce a fabric with loops of uniform height, the adhesive is applied to the base web 14 in lines evenly spaced apart and extending across the web. Furthermore, the spacing between the lines of adhesive may be increased or decreased to obtain a higher or a lower pile height, as desired. Referring to FIG. 25, one such adhesive pattern is illustrated in the form of evenly spaced diagonal lines 82. Another such adhesive pattern is illustrated in FIG. 26, in the form of lines 84, each in the shape of a sine wave. A brick-like pattern is another such pattern as shown in FIG. 27. If broken lines of adhesive are utilized to obtain element looping-such, for example, as the brick-like pattern of FIG. 27-the gaps in the lines of adhesive 86 should be staggered so that the web elements longitudinally span the spaces between the adhesive lines and are securely attached to the adhesive.

When the spacing of points of attachment of the fibers to the adhesive varies regularly over the area of the base web as, for example, when an open diamond pattern of adhesive is used, the loops in the finished fabric will vary in height in a regular manner to provide a uniformly varying surface having a textured appearance. When, onthe other hand, an open pattern of adhesive is used in which, in the cross direction of the base web 14, the lines of adv hesive are parallel, or evenly spaced, it will be seen that the spacing of points of attachment of the elements to the adhesive will be uniform over the total area of the fabric, and the loops in the finished fabric will be of uniform height to provide a more even surface. The appearance of such a surface will, of course, be affected by,the characteristics of the elements which form the loops. Thus, Where the elements are yarn or heavy strands,of fibers such, for example, as disclosed in the aforesaid copending application of Robert I. Stumf, WilliamI. Mattes and Herman G.,Minshell, Ser. No. 77,840, now U.S. Pat, No. 3,729,353, the, loops will be clearly visible, while where the elements are small diameter, flexible fibers, the surface will have a fibrous appearance, the fiber looping being less evident.

It has been observed that the transverse adhesive lines, when consolidated by the actionA of the gathering blade 38, are moved into proximity or abutment with each other and, being in a soft tacky state due to the high tempera.- ture of the heating drum 37, tend to bond to each other. However, the bond between lines of adhesive may be broken and the open pattern of adhesive substantially restored by drawing the fabric in the machine direction after the adhesive backing layer has been cooled, all as more clearly described in the aforesaid copending application Ser. No. 820,224, now U.S. Pat. No. 3,687,754. It may thus be demonstrated that the backing layer, while it appears to be continuous in the finished fabric, actually 17 comprises lines of adhesive extending in the cross direction of the fabric and bonded to each other.

In the application of the adhesive to the base web, it has been observed that by increasing the adhesive viscosity, a sharp, distinctvprinted pattern will be obtained such that the fibers are securely attached to the adhesive at distinct spaced points and are not embedded in adhesive throughout their length. It is desired to have spaced points of fiber adhesive attachment so that the fiber loops will be distinctly and separately formed at the gathering blade in such a manner as to extend outwardly from the adhesive bonding layer. Fiber sizes between 11/2 denier and- 15 denier have been successfully utilized in the base web 14 with a 1A inch diamond pattern of adhesive. With higher denier fibers, or with strands or yarns used in the preparation of the base web, the adhesive pattern is preferably enlarged or adhesive utilized in the form of a continuous layer, illustratively as disclosed in Ser. No. 856,793, now U.S. Pat. No. 3,720,554, with the points of fiber, strand or yarn embedment being spaced at somewhat larger distances, so as to improve the continuity of the adhesive backing in the fiber product and so as to insure attachment of the fibers or strands to the adhesive at spacings along the length thereof which will define the depth of pile or degree of loft in the finished material. With the light-weight webs of rayon used for the formation of the fabrics of Examples I-V, the ratio of fiber to adhesive was approximately 1:1. It has been found that the degree of adhesive fiber attachment in the base web was affected when the fiber-to-adhesive ratio with such type fibers was substantially increased above 1:1, so that the fiber loops did not form properly at the blade 38, nor did the fibers have sufficient attachment to the adhesive layer in the finished fabric. On the other hand, increasing the relative amount of adhesive in the base web had the result of producing a thicker adhesive layer in the finished material and more secure fiber attachment, but the adhesive lines tend to disperse so that the pattern becomes less open, thereby affecting the height of the loops, which is undesirable. The fiber-adhesive ratio will be different, however, for base webs of yarns and threads where it appears that less amounts of adhesive, relatively speaking, will provide adequate attachment of the loops to the adhesive backing layer.

TYPES OF ELEMENTS AND BASE WEBS While staple length rayon fibers lwere used for the preparation of the fabrics of Examples I to V, it should be noted that these specific Examples have been presented to illustrate the effect of varying various control parameters on the nature and quality of the finished material without implying that the process is in any way limited to this particular type of fiber. Other fibers that have been used in the process in its preferred form, and which have resulted in fabrics of excellent properties of hand, drape, and appearance, include natural fibers and various synthetic fibers and blends thereof.

`.For example, acrylic, olefin and polyester fibers have been used, and itis within the contemplation of the invention to use any or all of these Ifibers by themselves or in blends, as well as natural fibers, acetate, nylon and other synthetic fibers in staple length or in monofilament form, any of which may be used for the preparation of the base web 14. Moreover, not only highly drafted webs and carded webs of staple length fibers lmay be used for the base web, but, also, garneted and air-laid webs of such fibers as well as directly laid alined webs of monofilament. It has been noted, however, that when webs such as carded webs are used for the base web in which an important proportion of the fibers are randomly oriented, those fibers not alined with the machine direction appear to interfere with the loop production by the gathering blade. The most regular formation of loops with the loops turned normal to the machine direction has been produced with those base webs having the highest proportinr of fibers alined with the machine direction as, for

18 example, the highly drafted webs made with the apparatus illustrated schematically in FIG. l.

It is also contemplated that flexible threads, yarns or strands may be used for forming a base web, provided that the iiexibility of such elements is high enough to permit looping of the fibers and turning of the loops in the manner heretofore described. To obtain regular loops of such elements in the finished material, it is clear that substantially all such elements should be parallel and extend longitudinally of the web, for loop formation will be interfered with by those elements that substantially depart from such longitudinal alinement.

It has been found that in order to produce a material fully in accordance with the present invention, the elements should be sufficiently flexible to allow the loops to form and to twist normal to the machine direction while being formed under the action of the adhesive consolidating and gathering blade 38. Thus, neither stiff strands which do not loop under the action of the gathering blade 38, nor multiple strand yarns in which the lay of the strand opposes the tendency of the loops to twist while being formed under the action of the blade, will satisfactorily serve as elements of the base web 14 when it is desired to produce a fabric fully in accordance with the present invention.

It will, therefore, be seen that the features of the finished fabric are determined by the characteristics of the particular elements used in the formation of the base web 14 and, to some extent at least, by the nature of the process used in forming the base web. A further, specific fabric Example VI is illustrative, as shown in d: IG. 23.

EXAMPLE VI This fabric was made from a base web 14 prepared by carrying slivers of rayon fibers alternated with slivers of a combination of rayon and polypropylene fibers into the drafting frame 12 of IFIG. 1. By the drafting process, these alternate slivers were spread into bands 1/2 inches to 3A inches wide in the base web. Because of the relatively lofw softening temperature of polypropylene, as the web 14 was carried around the curing drum 29 during the base web formation stage of the process and raised to the temperature of the drum (300 F.), a substantial proportion of the polypropylene fibers were softened and shrunk. In the subsequent adhesive consolidation and fiber looping stage, the bands of polypropylene and rayon fibers were consolidated into dense, thin, hard strips 70 displaying relatively few of the fiber loop characteristics of the neighboring wider bands 72 of 100% rayon fibers, as illustrated in FIG. 23.

One means of utilizing the effect produced by softening or melting such synthetic fibers would be in the preparation of a fabric with a tear strip defined by a thin band of polypropylene or polyethylene fibers which, having been passed over the curing drum 29 and raised to substantially their softening temperature, have been made viscous and reduced to a low tensile strength film. Of course, the fabric of FIG. 23, with its combined polypropylene and rayon fiber strips 70, may be used for its decorative striped appearance.

In the foregoing Example VI, the heat from the curing drum 29 is utilized to soften thermoplastic fibers of the base web 14. It is one of the important features of the invention to utilize heat from the forming drum 37 to heat-set thermoplastic fibers in the web. The temperature of the forming drum is determined by the adhesive utilized and, typically, is maintained at a lower temperature than the temperature of the first stage adhesive curing drum 29 which is provided for the purpose of fusing the polyvinyl chloride or other resin of the adhesive, to thereby secure an adequate bond to the fibers. The temperature of the forming drum 37 is, however, preferably maintained at all times at a level suicient to reactivate the adhesive and make it tacky so that it will adhere to the drum 317. The forming drum temperature will not only depend on the particular adhesive used but, also, on the operating surface speed of the drum and the distance that the web is maintained in contact with the drum. The degree of heat-set that can be obtained depends on the softening temperature of thermoplastic fibers in the web. Thermoplastic fibers which are heated to their softening temperature will be heat-set into the looped or crimped shape that is imparted to such fibers by the gathering blade 38. The pile of the finished fabric embodying such heat-set fibers has resiliency and resists crushing, so that where these properties are desired, the thermoplastic fibers for the base web 14 should be selected with consideration of their softening temperature and the operating temperature of the forming drum.

It has also been observed that certain types of thermoplastic fibers will be shrunk by exposure to the heat of the curing drum 29 and/or the forming drum 37. Fiber shrinkage will, of course, affect the size of the loops formed Iby such fibers and, therefore, the appearance of the `finished material. Fiber shrinkability at the operating temperature of the curing drum 29 and the forming drum 37 must, therefore, also be considered in selecting the fiber for the base web 14.

ADDITIONAL METHOD STEPS The method of the present invention, in its preferred form, involves the preparation of an adhesive bonded, highly drafted base web 14, and the adhesive consolidation and fiber looping accomplished by the cooperating action of the gathering blade 38 and the forming drum 37. Additional preliminary steps in the formation of the base web 14, as well as subsequent steps for processing the fabric 40 after it flows from the gathering blade 38, may be optionally carried out to alter the characteristics of the yfinished fabric.

Preliminary Steps Referring to FIG. 1, the base web 14, as has been previously described, may be formed of webs from two drafting frames 12, 25 supplied with staple length fibers or monofilament. As an important feature of the invention, patterns of color or of fibers which differ from the main constituent of the fabric may be introduced into the finished fabric 40 by utilizing certain preliminary steps in the formation of the base webs.

For example, the underweb from the first drafting frame 12 may be made from fibers of a solid color while at spaced intervals across the base web 14a bands of one or more colors may be introduced by passing colored fibers through the second draw frame 25 so that the colored fibers are laid on the underweb 14a. The top layer 14b of yfibers may be applied in the pattern desired and, it has been found, will effectively screen out the underweb color in most instances so that the finished material will display a striped appearance.

The top layer 14b of fibers from the draw frame 25 may also be introduced in a wavy or saw-tooth pattern to produce either a wavy or saw-tooth effect completely across the fabric, as illustrated in FIG. 2, or in bands across the fabric as desired.

Alternatively, the under layer 14a of the base web 14 may embody different colored fibers by having the fibers at the margins, for example, of one color while the fibers across the center of the web are of a different color or colors. To this end, different colored fibers may be introduced through either or both draw frames 12 and/ or 25. The top layer of fibers may be in the form of spaced bands of fibers across the web, or the different color may be introduced through only the second draw frame 25 by laying down a uniform layer of fibers in which at least certain of the adjacent slivers are of different colors. Where the top layer of the base web comprises spaced bands of fibers, it will be appreciated that the finished fabric will have a varying weight across the web, with a double weight and a more dense mass of loops in the bands where the top fibers are laid down.

Other procedures may be used for introducing patterns into the finished fabric. For example, a layer of fibers in the form of a section of `a web from the second draw frame 25 may be laid on a web from the first draw frame 12 or onto a carded web underlayer. Due to the consolidation operation performed by the gathering blade 38, the pattern will be shortened lengthwise but not appreciably disarranged laterally, such that whatever the pattern introduced into the top layer of the base web 14, it will appear in the finished fabric in its fore-shortened form. A pattern of fibers may be introduced into the top draw frame 25, which will operate to aline the fibers and will draw or extend the pattern in the machine direction. The subsequent shortening effect by the gathering blade 38 will tend to reduce the pattern to its original form in those instances where the extent of the draw in the drafting frame 25-illustrative1y 15:1-is approximately the same as the take-away ratio.

Subsequent Steps As shown in FIG. l, the fabric 40 is carried along the take-away surface 41 by the action of the conveyor 52. Since the adhesive backing is hot and tacky as the fabric flows onto the take-away surface 41, that surface may be treated with a non-stick or release coating to insure that the fabric may be drawn smoothly along the surface.

To cool the belt of the conveyor 52 and prevent it from becoming overheated from the hot adhesive back of the fabric 40, streams of air may be blown against the underside of the belt from suitably placed air nozzles 54. This will also serve to cool the fabric 40, although it may be necessary or desirable to pass the fabric through a cooling station or zone (not shown) to cool the adhesive and thermoplastic fibers to temperatures below their softening temperatures or to eliminate tackiness of the adhesive.

With fabrics made from thermoplastic fibers such as acrylic fibers, it has been found that with the forming drum 37 operating at about 260 F., the fibers are heatset in the crimped or looped form produced by the action of the gathering blade 38. As a further process step, and as more fully disclosed in the aforesaid copending application of Robert I. Stumpf, Ser. No. 820,224, now U.S. Pat. No. 3,687,754, such fabric 40 may be pulled or drawn in the machine direction to expand and open the adhesive backing layer. The set in such fibers will tend to return the fabric to its consolidated form, such that the fabric is stretchable and elastic up to a limit of about The backing layer of the fabric 40 may be perforated as yet another procedure for opening the adhesive layer to provide a stretchable fabric.

In furtherance of the present invention, provision may be made for laminating the fabric 40 to an additional backing layer. To this end, and as best illustrated by reference to FIGS. 28a and 28b conjointly, the fabric 40 may be carried directly from the adhesive compacting and fiber looping section 30 to a laminating station 90 wherein n laminations (where n equals any desired whole integer) may be adhesively bonded to the back of the fabric 40.

For example, in those instances where it is desirable to reinforce the fabric 40 because of the particular end use to which the fabric is to be put, it may be desirable to laminate the fabric to a backing material suchs as an open scrim, indicated generally at 91 in FIGS. 28a and 28b. As here shown, the scrim lamination is drawn from a supply roll 92 and fed around a turning roll 94 into direct face-to-face contact with the compacted adhesive backing layer of the high-loft fabric 40, which backing layer may still be hot and tacky. The scrim layer 91 and fabric 40 are then drawn around a heated drum 95 where the adhesive backing layer on the fabric 40 is reactivated and fusing of the adhesive and the scrim layer 91 is substantially completed while the scrim layer is maintained in firm contact therewith to bond the fabric to the scrim. 

